Peel-away shaker can and can membrane

ABSTRACT

The present invention relates to container laminate and container having a container laminate through which materials may be accessed and/or dispensed. The laminate has multiple layers that are peeled away when opened to reveal one or more openings in a layer that remains adhered to the container after opening.

CROSS-REFERENCE TO A RELATED APPLICATION

This application is a continuing divisional application of copendingapplication Ser. No. 14/556,553, filed Dec. 1, 2014, which isincorporated herein in its entirety by reference.

The present application claims priority to U.S. Provisional PatentApplication Ser. No. 61/913,082, filed Dec. 6, 2013, incorporated hereinby reference in its entirety.

FIELD OF THE INVENTION

The present invention relates generally to containers for housing anddispensing materials that can be shaken or withdrawn from the containerthrough one or more openings, and more particularly to peel-awaymembranes employed in such containers.

BACKGROUND OF THE INVENTION

Containers are often employed for housing dispensing granular materials,particularly in the food industry. Salt, pepper, cinnamon, and sugar areamong the various materials that can be dispensed from a container,typically through holes or orifices cut in a member or top of thecontainer. While the present invention is useful in the food productindustry, the invention is not limited thereto, and the invention may beused for any container from which a product is dispensed and for whichthe present peel-away shaker designs and configurations may be employed.One such exemplary dispensed granular material is powdered carpetdeodorizer. Moreover, the laminate membrane may be employed oncontainers made of any types of materials, including plastics,composites, papers, and any other container-making material.

Other containers that have peel-away membranes have one or more openingsthrough which product may be accessed. For example, certain containersmay have openings through which a spoon, straw, or other utensil may beinserted so that product within the container may be withdrawn.

SUMMARY OF THE INVENTION

According to one aspect, a multi-layered peel-away dispensing laminateis provided that includes a metalized polymeric layer for adhering to acontainer wherein the metalized polymer layer has an upper surface and alower surface, the metalized polymeric layer defining at least onediecut opening therethrough; a pressure sensitive adhesive adhered to atleast a portion of the upper surface of the metalized polymeric layer;and a peelable film layer having an upper surface and a lower surfacewherein the lower surface of the peelable film layer is adhered to atleast a portion of the upper surface of the metalized polymeric layer bythe pressure sensitive adhesive

According to an aspect, the present invention provides a multi-layeredpeel-away dispensing laminate that may have a metalized polymeric layerfor adhering to a container wherein the metalized polymer layer has anupper surface and a lower surface, the metalized polymeric layerdefining at least one opening therethrough; a pressure sensitiveadhesive adhered to at least a portion of the upper surface of themetalized polymeric layer; a peelable film layer having an upper surfaceand a lower surface wherein the lower surface of the peelable film layeris adhered to at least a portion of the upper surface of the metalizedpolymeric layer by the pressure sensitive adhesive; an adhesive layeradhered to the upper surface of the peelable film layer; and a paperlayer adhered to the upper surface of the peelable film layer by theadhesive layer.

According to another aspect, the present invention provides a containerhaving a multi-layered peel-away dispensing laminate that may have ametalized polymeric layer for adhering to a container wherein themetalized polymer layer has an upper surface and a lower surface, themetalized polymeric layer defining at least one opening therethrough; apressure sensitive adhesive adhered to at least a portion of the uppersurface of the metalized polymeric layer; a peelable film layer havingan upper surface and a lower surface wherein the lower surface of thepeelable film layer is adhered to at least a portion of the uppersurface of the metalized polymeric layer by the pressure sensitiveadhesive; an adhesive layer adhered to the upper surface of the peelablefilm layer; and a paper layer adhered to the upper surface of thepeelable film layer by the adhesive layer.

According to another aspect, the present invention provides a method foropening a container for dispensing granular particles therefrom whereinthe container has a multi-layered peel-away dispensing laminate that mayhave a metalized polymeric layer for adhering to a container wherein themetalized polymer layer has an upper surface and a lower surface, themetalized polymeric layer defining at least one opening therethrough; apressure sensitive adhesive adhered to at least a portion of the uppersurface of the metalized polymeric layer; a peelable film layer havingan upper surface and a lower surface wherein the lower surface of thepeelable film layer is adhered to at least a portion of the uppersurface of the metalized polymeric layer by the pressure sensitiveadhesive; an adhesive layer adhered to the upper surface of the peelablefilm layer; and a paper layer adhered to the upper surface of thepeelable film layer by the adhesive layer, wherein the peelable film andpaper layers are peeled away from the metalized polymeric layer.

According to another aspect, the present invention provides a method foropening a container for accessing products housed within the containerwherein the container has a multi-layered peel-away dispensing laminatethat may have a metalized polymeric layer for adhering to a containerwherein the metalized polymer layer has an upper surface and a lowersurface, the metalized polymeric layer defining at least one openingtherethrough; a pressure sensitive adhesive adhered to at least aportion of the upper surface of the metalized polymeric layer; apeelable film layer having an upper surface and a lower surface whereinthe lower surface of the peelable film layer is adhered to at least aportion of the upper surface of the metalized polymeric layer by thepressure sensitive adhesive; an adhesive layer adhered to the uppersurface of the peelable film layer; and a paper layer adhered to theupper surface of the peelable film layer by the adhesive layer, whereinthe peelable film and paper layers are peeled away from the metalizedpolymeric layer.

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate one or more embodiments of theinvention and, together with the description, serve to explain theprinciples of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including thebest mode thereof directed to one of ordinary skill in the art, is setforth in the specification, which makes reference to the appendeddrawings, in which:

FIG. 1 shows exemplary opening designs for dispensing of and/or accessto materials from containers of the present invention;

FIG. 2 is a side view showing layers of an exemplary laminate of a firstembodiment of the present invention;

FIG. 3 is a side view showing layers of another exemplary laminate of asecond embodiment of the present invention;

FIG. 4 is a side view showing the laminate structure of the secondembodiment shown in FIG. 3 before opening;

FIG. 5 is a side view showing the laminate structure of the secondembodiment shown in FIG. 3 after opening;

FIG. 6 is a top view of an exemplary undercut laminate of the presentinvention;

FIGS. 7A and 7B show additional exemplary designs for the openings fordispensing of and/or access to materials from containers of the presentinvention;

FIGS. 8A-8D are photographs of a prototype structure of the presentinvention showing the process of opening the container and peeling awaythe present inventive laminate membrane.

Repeat use of reference characters in the present specification anddrawings is intended to represent same or analogous features or elementsof the invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Reference will now be made in detail to certain embodiments of theinvention, one or more examples of which are illustrated in theaccompanying drawings. Each example is provided by way of explanation ofthe invention, not limitation of the invention. In fact, it will beapparent to those skilled in the art that modifications and variationscan be made in the present invention without departing from the scope orspirit thereof. For instance, features illustrated or described as partof one embodiment may be used on another embodiment to yield a stillfurther embodiment. Thus, it is intended that the present inventioncovers such modifications and variations as come within the scope of theappended claims and their equivalents.

In one embodiment, a beaded composite can with a die-cut multi-layerlaminate membrane to create a dispensing feature for use in shakerapplications is provided and exemplified herein. Specifically, such adie-cut laminate membrane may replace the typical rigid metal or plasticshaker tops on a powdered shaker dispenser (e.g., salt, pepper, or spiceshakers or carpet powder shakers, etc.). Additionally, the laminate mayalso have registered graphics for advertising and color printing. Suchprinting may be on the surface of a layer or between the layers of filmto create various gaming, couponing, or other promotional features. Thelaminate die-cut pattern may be customized for the particular product tobe dispensed or accessed. The patterns can be any shape, size, orconfiguration to create an opening for shake-dispensing of a powder,creating a spoon slot, or creating a pour spout.

Various configurations for the container openings through which productsmay be dispensed or accessed are illustrated in FIG. 1. However, theinvention is not limited to any particular container opening and anyopening through which product may be dispensed or access is applicablehereto.

In most embodiments, the openings will be die-cut through the laminatestructures employed for the membranes that seal the containers. Anexemplary structured laminate may be constructed in the layered formatshown in FIG. 2.

As shown in FIG. 2, the upper layer of the laminate may have a printsurface. For example, the upper layer may be paper, film, foil, oranything printable on at least one surface. The printable surface willbe the outer surface of the laminate that is visible to the consumerwhen viewing the top of the container.

The next layer below the upper layer is a pressure sensitive adhesivelayer (PSA). It is used for attaching the lower surface of the upperprintable layer to the upper surface of a bottom layer that is apeel-away (i.e., release) layer. In certain embodiments, the PSA may bea water-based acrylic PSA.

The bottom layer is typically a oriented polypropylene (mOPP) materialand a layer such as a film, polyethylene, polyethylene terephthalate(PET), etc. that is adhered to the container. Die-cuts are made throughthe bottom layer for both the tab release feature described herein aswell as for the dispensing aspects.

Another, more detailed laminate structure, is shown in FIG. 3. As shownin FIG. 3, the bottom-most layer (F1) is a metalized orientedpolypropylene (mOPP) material sealed with a polyethylene sealant.Oriented polypropylene (OPP) is a known packaging multilayer film with asurface layer that is heat weld/seal compatible with high densitypolyethylene (HDPE) resins. The sealant layer may be modified with anypolymer material to promote additional adhesion to the selectedcontainer to which the laminate is adhered, particularly rigidcontainers. In addition, when used in the present invention, this layermay, optionally, have a vacuum-deposited aluminum on one side to createan improved barrier and shiny metallic look. The sealable side islocated toward the interior of the dispenser and the shiny, metalizedside will be facing outward adjacent to the next PSA (C1) layer. Thetypical thickness of the mOPP layer may be about 0.0011 inch, but otherthicknesses may be utilized as well.

The layer adjacent to the mOPP layer is a pressure sensitive adhesive(PSA) layer (C1). This layer may be applied to the layered laminate byseveral processes, including a registered pattern gravure process.

The next layer is an optional ink layer (C2). If included, it can be aprimer layer or, optionally, it can contain graphics for advertisingpurposes.

The layer adjacent the adhesive PSA layer may be a biaxially-orientedclear polyester polyethylene terephthalate (PET) film layer (F2). Thethickness of the PET may vary according to the particular environment,but may typically have a thickness of 0.00092 inch. In addition, the PETlayer may be a metalized or coated PET film, or other similar layerdesigned to promote barrier properties against moisture and oxygen. Itcould also be another film type such as OPP or oriented polyamide (OPA),which is commonly known as nylon film.

The next layer is an adhesive layer (C3) to bind the outer paper layerto the PET layer. The adhesive layer, in some embodiments, can be aurethane adhesive or, alternatively, the layer can be extruded withpolyethylene. Any number of adhesives, known to those in the art, thatare sufficient to adhere the paper layer to the PET layer may be used.

The next layer is the paper layer (F3), which may be formed of a paper(such as a 35 lb/ream bleached kraft that is coated on one side with aclay-based coating). Ink is then printed onto the clay-coated paperlayer surface by a printing process such as flexo or gravure printing.

Finally, an optional overlaquer (OL) layer (C4) may be applied as thefinal, outer layer in order to provide a protective coating over theink.

The peel-away features of the present membrane are provided by ascoremarking process as follows. A tab scoremark allowing the laminateto split between the PSA layer (C1) and the mOPP layer (F1) so that thetop layers that include the PSA layer (C1) and all layers above (C2, F2,C3, F3, C4) may be peeled away from the container when opening, whileallowing the mOPP layer (F1) to remain heat-welded to the can. Inaddition, if the optional ink layer is included between the PSA (C1) andPET (F2) layers as explained above, the ink layer will removed alongwith the upper layers.

The structure of the laminate membrane before opening is illustrated inFIG. 4 and the structure of the laminate membrane after opening isillustrated in FIG. 5.

In other alternative embodiment, other cuts, such as the multipleundercuts shown in FIG. 6 may be utilized to allow for robustregistration and/or a PSA knockout(s). In such embodiments, theundercuts direct force away from the bead and to the PSA/mOPP interfaceduring peeling away and opening of the container. As shown in FIG. 5,the original single die-cut line that was the initiator of laminatesplit has been replaced. Multiple parallel/concentric lines makes iteasier for the lamination split to occur and will make the membrane morerobust to changes in registration. In addition, multiple/concentricundercuts increase the odds that a tab die-cut is adjacent to the sealarea on the bead.

Additional designs for the die-cut openings are shown in FIG. 7A,wherein PSA Knockouts are shown in green. The corresponding undercutdies for such openings are shown in FIG. 7B.

Secondly, in the designs shown in FIGS. 4 and 5, the PSA layer (C1) isshown as having 100% coverage and without skips. The “PSA Knockout”shown in FIG. 8, which also illustrates the multiple undercuts, meansthat the PSA is pattern-applied (and registered to the die-cuts) so thatthere is no PSA in that area. This further facilitates easy laminationsplitting because there is no adhesion at this area as it will be“pre-split”. The force applied during opening is directed at thepeel-off layer (top label removal) and not at the interface between themOPP and the adhesive bead on the rim of the container.

An embodiment of the invention and the process employed for opening acontainer employing the present invention are shown in the photographsin FIGS. 8A-8D. FIG. 8A shows the top of the laminate structure, with aview of the upper paper layer (F3), mounted onto a container. In thisparticular prototype, no ink or overlaquer layer is employed. FIG. 8Bshows a bottom view of the tab that is used to pull the peel-awaycomponents of the membrane when opening the container. The brightmetallic structure is a portion of the metalized OPP (mOPP) layer F1.

Opening of the container is initiated as shown in FIG. 8C with the tabbeing grasped and the peel-away beginning. The white of the paper layeris seen from below and through the transparent PSA/optional layer andadhesive. The splitting of the layers happens at the score mark that issituated between the tab and the edge of the can. FIG. 8D illustratesthe further pulling away of the layers that reveals a pattern ofperforations. Where there are holes in the mOPP layer, there is acorresponding metallic circle that remains adhered to the PSA. The holesin the mOPP layer remaining adhered to the container opening areemployed for dispensing a granular material in this exemplaryembodiment.

EXAMPLES

The following variations of the laminate of the present invention werecreated and tested for use as peel-away laminate membranes. However, itis to be understood that the components of the membranes set forthherein are exemplary in nature only and that any components capable ofperforming the specific performances required for the working of theinvention described herein may be utilized.

TABLE 1 Layer* Example 1 Example 2 Example 3 Example 4 Example 5 C4overlaquer/1 overlaquer/1 overlaquer/1 overlaquer/1 overlaquer/1 colorink color ink color ink color ink color ink F3 30# Paper 30# Paper 30#Paper 70# Paper 70# Paper C3 2 part 2 part 2 part 2 part 2 part urethaneurethane urethane urethane urethane F2 0.00092″ PET 0.00092″ PET0.00092″ PET 0.00092″ PET 0.00092″ PET C2 Ink primer for Ink primer forInk primer for Ink primer for Ink primer for PSA PSA PSA PSA PSA C1Pattern PSA Pattern PSA 100% PSA Pattern PSA Pattern PSA flood coat withpattern PSA at certain points F1 0.0011″ 0.0011″ 0.0011″ 0.0011″ 0.0011″mOPP mOPP mOPP mOPP mOPP *Layers refer to the layers as shown in FIG. 2

These and other modifications and variations to the present inventionmay be practiced by those of ordinary skill in the art, withoutdeparting from the spirit and scope of the present invention, which ismore particularly set forth in the appended claims.

In addition, it should be understood that aspects of the variousembodiments may be interchanged in whole or in part. Furthermore, thoseof ordinary skill in the art will appreciate that the foregoingdescription is by way of example only, and is not intended to limit theinvention so further described in such appended claims. Therefore, thespirit and scope of the appended claims should not be limited to thedescription of the versions contained therein.

What is claimed is:
 1. A multi-layered peel-away dispensing laminatecomprising: a. a polymeric layer for adhering to a container wherein thepolymeric layer has an upper surface and a lower surface, the polymericlayer defining at least one diecut opening therethrough; b. a pressuresensitive adhesive adhered to at least a portion of the upper surface ofthe polymeric layer; and c. a peelable film layer having an uppersurface and a lower surface wherein the lower surface of the peelablefilm layer is adhered to at least a portion of the upper surface of thepolymeric layer by the pressure sensitive adhesive.
 2. A multi-layeredpeel-away dispensing laminate comprising: a. a polymeric layer foradhering to a container wherein the polymeric layer has an upper surfaceand a lower surface, the polymeric layer defining at least one openingtherethrough; b. a pressure sensitive adhesive adhered to at least aportion of the upper surface of the polymeric layer; c. a peelable filmlayer having an upper surface and a lower surface wherein the lowersurface of the peelable film layer is adhered to at least a portion ofthe upper surface of the polymeric layer by the pressure sensitiveadhesive; d. an adhesive layer adhered to the upper surface of thepeelable film layer; and e. a paper layer adhered to the upper surfaceof the peelable film layer by the adhesive layer.
 3. The laminate ofclaim 2, wherein the paper layer comprises an ink.
 4. The laminate ofclaim 3, wherein the ink is printed onto the paper layer.
 5. Thelaminate of claim 3, further comprising an overlaquer adhered to theupper surface of the paper layer and over the ink.
 6. The laminate ofclaim 1, wherein the pressure sensitive adhesive is registered.
 7. Thelaminate of claim 2, wherein the pressure sensitive adhesive isregistered.
 8. The laminate of claim 1, wherein the laminate comprisesscoremarks in order to allow knockouts when layers of the laminate arepeeled away when the container is opened.
 9. The laminate of claim 2,wherein the laminate comprises scoremarks in order to allow knockoutswhen layers of the laminate are peeled away when the container isopened.
 10. A container having an open end and comprising the laminateof claim 1 adhered to the open container end.
 11. A container having anopen end and comprising the laminate of claim 2 adhered to the opencontainer end.